Modular robotic floor-cleaning system

ABSTRACT

Some aspects provide a floor cleaning system, including: a robot, including: a chassis; a set of wheels; a processor; a plurality of sensors; a vacuum module; a mopping module; a dustbin module for storing debris; a cleaning fluid tank module for storing cleaning fluid; and a rechargeable battery module; and a base station; wherein: the base station is configured to empty debris stored within the dustbin module; the base station is configured to replenish the cleaning fluid tank module with cleaning fluid; and the robot navigates to the base station when a rechargeable battery charge of the rechargeable battery module is below a first threshold during operation and departs the base station to continue operation when the rechargeable battery charge is above a second threshold.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of Non-Provisional patent application Ser. No. 16/726,471, filed Dec. 24, 2019, which is a Continuation of Non-Provisional patent application Ser. No. 14/997,801, filed Jan. 18, 2016, which claims the benefit of U.S. Provisional Patent Application No. 62/114,569, filed Feb. 10, 2015, each of which is hereby incorporated by reference.

FIELD OF THE DISCLOSURE

The disclosure relates to automated floor-cleaning systems.

BACKGROUND

Robotic appliances have become increasingly popular for cleaning residential homes. Vacuuming and mopping robots are frequently used to clean floors. These devices, however, are not widely used in commercial settings. One reason for this is that robotic appliances often require servicing (emptying of debris, replacement of cleaning liquid) too frequently to be practical for cleaning very large areas. A need exists for a method to allow a mobile robotic cleaning device to operate for longer periods of time and cover larger spaces without requiring frequent maintenance.

SUMMARY

Some embodiments include a floor cleaning system, including: a robot, including: a chassis; a drive system including a set of wheels to enable movement of the robot; a control system in communication with the drive system including a processor operable to control the drive system to provide at least one movement pattern; a cleaning assembly; two or more modules comprising at least a rechargeable battery and a dustbin; and a means for navigating; and a base station; wherein the robot navigates to the base station during an operation when a rechargeable battery charge is below a first particular threshold and departs the base station to continue operation when the rechargeable battery charge is above a second particular threshold.

Some aspects provide a floor cleaning system, including: a robot, including: a chassis; a set of wheels; a processor; a plurality of sensors; a vacuum module; a mopping module; a dustbin module for storing debris; a cleaning fluid tank module for storing cleaning fluid; and a rechargeable battery module; and a base station; wherein: the base station is configured to empty debris stored within the dustbin module; the base station is configured to replenish the cleaning fluid tank module with cleaning fluid; and the robot navigates to the base station when a rechargeable battery charge of the rechargeable battery module is below a first threshold during operation and departs the base station to continue operation when the rechargeable battery charge is above a second threshold.

Some aspects include a method for operating a robot and a corresponding base station, including: cleaning, with a vacuum module and mopping module of the robot, an environment; emptying, with the base station, debris stored within a dustbin module of the robot; replenishing, with the base station, a cleaning fluid tank module of the robot with cleaning fluid; and recharging, with the base station, a rechargeable battery module of the robot when a rechargeable battery charge of the rechargeable battery module is below a first threshold during operation, wherein: the robot autonomously navigates to the base station to recharge the rechargeable battery module when the rechargeable battery charge is below the first threshold; and the robot departs the base station to continue operation when the rechargeable battery charge is above a second threshold.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1A illustrates an overhead view of a floor-cleaning robot, according to some embodiments.

FIG. 1B illustrates an overhead view of a base station containing extra modules, according to some embodiments.

FIG. 2 illustrates an overhead view of a base station containing extra modules and a repository for storing used modules, according to some embodiments.

FIG. 3 illustrates the process of a floor-cleaning robot exchanging a used module for a new module, according to some embodiments.

FIG. 4 illustrates a floor-cleaning robot loading a new module from a base station, according to some embodiments.

FIG. 5 illustrates an example of a robot, according to some embodiments.

DETAILED DESCRIPTION OF SOME EMBODIMENTS

The present invention will now be described in detail with reference to a few embodiments thereof as illustrated in the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without some or all of these specific details. In other instances, well known process steps and/or structures have not been described in detail in order to not unnecessarily obscure the present invention.

Generally, the disclosure relates to a modular robotic floor-cleaning system suitable for cleaning large spaces. Some embodiments provide a robotic floor-cleaning system that requires a minimal amount of maintenance. Some embodiments provide a robotic floor-cleaning system that can operate for extended periods of time and cover large amounts of surface area with a minimum of stoppages. Some embodiments provide a robotic floor-cleaning system that can effectively service large scale or commercial locations.

Some embodiments provide a modular robotic floor-cleaning system. In some embodiments, a mobile cleaning robot has modules for each of its functions that collects or uses materials, substances, or resources. For example, a vacuuming module, a mopping module, a polishing module, and rechargeable battery module may be provided. In some embodiments, a separate base station stores new modules, so that when modules are expended, they may be exchanged for new modules. For example, once the vacuuming dustbin module is full, the robot returns to the base station and exchanges the full dustbin module for an empty dustbin module.

In some embodiments, a floor-cleaning robot has modules for each of its functions that collect or consume resources. In some embodiments, the modules may be ejected and replaced as necessary. In some embodiments, a synchronized base station stores new modules and, in some embodiments, may also contain a repository for used modules. In some embodiments, the robot returns to the base station periodically, ejects expended modules, and loads new modules. In some embodiments, exchange of modules may be triggered by sensors that detect when a module has been expended. In some embodiments, exchange of modules may simply occur at predetermined intervals based on the run time of the system. In some embodiments, materials, substances, or resources of modules may be emptied or replenished after a particular amount of operational time or a particular distance travelled. In some embodiments, when the material, substance, or resource of a module must be emptied or replenished the robot may return to the base station or may switch from the functionality corresponding with the module to another functionality corresponding with another module. The system can thus continue working without waiting for human assistance in emptying, cleaning, or refilling modules.

FIG. 1A illustrates an example of an overhead view of a floor-cleaning robot 100. In the example shown, the robot has four modules 101. It should be noted that any number of modules may be provided without departing from the scope of the invention; the example shown is meant to be illustrative, rather than restrictive. Modules may have different functions related to the system capabilities. For example, a floor-cleaning robot may contain a dustbin module where vacuumed debris is stored, a cleaning fluid tank module where cleaning fluid for mopping the floor is stored, a water tank module where water for steaming the floor is stored, a polishing module where wax or another polishing agent for polishing a floor is stored, and a battery module where a battery for supplying power to the system is stored. Other types of modules may be provided without limitation; these examples are meant to be illustrative rather than restrictive. Modules may be devised to serve the particular capabilities of floor-cleaning system in question.

FIG. 1B illustrates an example of a base station 102 storing extra unused modules 103. A base station is not limited in size and may contain any number of modules without limitation.

In some embodiments, the base station further comprises a repository for storing ejected/expended modules. FIG. 2 illustrates an example of a base station 202. The base station comprises extra unused modules 203 and also has an area where used modules may be received. Used modules may be ejected into the empty slots 204.

In some embodiments, the floor-cleaning robot carries out operation as normal until it reaches any of a predetermined time limit, a predetermined stopping point, or a sensed state.

FIG. 3 illustrates an example of the process of exchanging modules during operation. In a first step 300, the floor-cleaning robot operates using the modules positioned within the body of the device. In a next step 301, the system determines whether any module has been expended. In some embodiments, sensors positioned within modules detect when a module is expended. In some embodiments, sensors determine remaining capacity of modules. For example, in a vacuum dustbin module, a sensor may detect when the module is full. For example, in cleaning fluid tank modules, water tank modules, and polishing modules, a sensor may detect when the module is empty. For example, in a battery module, a voltmeter may detect when the battery is discharged. In some embodiments, a timer indicates that modules are expended after a predetermined amount of running time. In some embodiments, a user may provide input instructing the system that a module is expended. If no modules are expended, the device continues work normally. Upon detection that one or more modules has been expended, the method proceeds to a next step 302 to navigate to the base station. In some embodiments, the system may be provided with mapping technology by which the robot may localize itself and the base station within a map of the environment and navigate to the base station. In some embodiments, the robot uses a mapping system and/or odometry to navigate to the base station. In some embodiments, the floor-cleaning robot uses sensors to detect and navigate to the base station. The specific methods for navigating to the base station are not part of the scope of the invention, so a detailed description thereof is not provided. In a next step 303, the expended module or modules are ejected from the robot. Numerous methods for ejecting units from devices exist and are used across many fields; any available method may be used to eject the module from the robot. Specific methods for ejecting modules from the robot are not part of the scope of the invention, therefore a detailed description thereof is not provided. In a next step 304, a new module to replace the ejected module is loaded from the base station into the floor-cleaning robot. Numerous methods for loading units into devices exist and are used across many fields; any available method may be used to load the module into the robot. Specific methods for loading modules into the robot are not part of the scope of the invention, therefore a detailed description thereof is not provided. The system then continues operation as normal.

FIG. 4 illustrates an example of the loading of a module from a base station into a robot. The robot 400 contains three modules 401 and has one open slot 402. The robot aligns the open slot 402 with the module 403 in the base station 405 that is to be loaded into the open slot. Any method for aligning the robot with the target may be used. Methods for alignment are widely used in the field and are not part of the scope of the invention, therefore a detailed description thereof is not provided. Once the slot is correctly aligned, the new module 403 may be loaded from the base station into the robot. The module is moved in a direction 404 into the slot 402. When the module is fully loaded into the slot, the robot may continue operation as normal.

FIG. 5 illustrates an example of a robot including a chassis 500, a set of wheels 501, a processor 502, a plurality of sensors 503, and a cleaning assembly 504.

In some embodiments, a single base station may serve groups of floor-cleaning robots. In some embodiments, a base station containing modules for all the floor-cleaning robots in a group may be positioned in a central location where all the robots in the group may access it to load new modules as needed. 

1. A floor cleaning system, comprising: a robot, comprising: a chassis; a set of wheels; a processor; a plurality of sensors; a vacuum module; a mopping module; a dustbin module for storing debris; a cleaning fluid tank module for storing cleaning fluid; and a rechargeable battery module; and a base station; wherein: the base station is configured to empty debris stored within the dustbin module; the base station is configured to replenish the cleaning fluid tank module with cleaning fluid; and the robot navigates to the base station when a rechargeable battery charge of the rechargeable battery module is below a first threshold during operation and departs the base station to continue operation when the rechargeable battery charge is above a second threshold.
 2. The floor cleaning system of claim 1, wherein the base station is configured to clean at least a portion of the mopping module.
 3. The floor cleaning system of claim 1, wherein the robot navigates to the base station to empty the debris stored in the dustbin module based on a particular interval.
 4. The floor cleaning system of claim 1, wherein the robot navigates to the base station to empty the debris stored in the dustbin module based on at least a user instruction.
 5. The floor cleaning system of claim 1, wherein: a first sensor indicates an amount of cleaning fluid stored within the cleaning fluid tank module; and the robot navigates to the base station to replenish the cleaning fluid tank module with cleaning fluid based on the amount of cleaning fluid stored within the cleaning fluid tank module.
 6. The floor cleaning system of claim 1, wherein the robot navigates to the base station to replenish the cleaning fluid tank module with cleaning fluid based on at least user instruction.
 7. The floor cleaning system of claim 1, wherein: a second sensor indicates an amount of debris stored within the dustbin module; and the robot navigates to the base station to empty the dustbin based on the amount of debris stored within the dustbin module.
 8. The floor cleaning system of claim 1, wherein a voltmeter detects the rechargeable battery charge of the rechargeable battery module.
 9. The floor cleaning system of claim 1, wherein at least odometry information is used in navigating the robot.
 10. The floor cleaning system of claim 1, wherein at least one other robot shares the base station with the robot.
 11. The floor cleaning system of claim 1, wherein the base station comprises: a first repository for storing one or more used modules; and a second repository for storing one or more new modules corresponding to a robot cleaning function, the one or more new modules having never been used previously by the floor cleaning system.
 12. The floor cleaning system of claim 11, wherein: the robot ejects a used module from a module slot of the robot into the first repository of the base station; and the base station loads a new module from the second repository of the base station into the module slot of the robot.
 13. A method for operating a robot and a corresponding base station, comprising: cleaning, with a vacuum module and mopping module of the robot, an environment; emptying, with the base station, debris stored within a dustbin module of the robot; replenishing, with the base station, a cleaning fluid tank module of the robot with cleaning fluid; and recharging, with the base station, a rechargeable battery module of the robot when a rechargeable battery charge of the rechargeable battery module is below a first threshold during operation, wherein: the robot autonomously navigates to the base station to recharge the rechargeable battery module when the rechargeable battery charge is below the first threshold; and the robot departs the base station to continue operation when the rechargeable battery charge is above a second threshold.
 14. The method of claim 13, further comprising: cleaning, with the base station, at least a portion of the mopping module.
 15. The method of claim 13, wherein the robot navigates to the base station to empty the debris stored in the dustbin module based on a particular interval.
 16. The method of claim 13, wherein the robot navigates to the base station to empty the debris stored in the dustbin module based on at least a user instruction.
 17. The method of claim 13, wherein: a first sensor disposed on the robot indicates an amount of cleaning fluid stored within the cleaning fluid tank module; and the robot navigates to the base station to replenish the cleaning fluid tank module with cleaning fluid based on the amount of cleaning fluid stored within the cleaning fluid tank module.
 18. The method of claim 13, wherein the robot navigates to the base station to replenish the cleaning fluid tank module with cleaning fluid based on at least user instruction.
 19. The method of claim 13, wherein: a second sensor disposed on the robot indicates an amount of debris stored within the dustbin module; and the robot navigates to the base station to empty the dustbin based on the amount of debris stored within the dustbin module.
 20. The method of claim 13, wherein: the base station comprises: a first repository for storing one or more used modules; a second repository for storing one or more new modules corresponding to a robot cleaning function, the one or more new modules having never been used previously by the floor cleaning system; the method further comprises: ejecting, with the robot, a used module from a module slot of the robot into the first repository of the base station; and loading, with the base station, a new module from the second repository of the base station into the module slot of the robot. 